Electrolytic cell and an electrode cartridge thereof

ABSTRACT

An electrolytic cell comprising, a housing having a channel extending there through and an opening formed in the housing for receiving an electrode cartridge, an inlet allowing water to pass into the channel, an outlet allowing water to pass from the channel, and a removable electrode cartridge comprising, a support member, having a outer side an inner side, the support member being adapted to close off the opening in the housing when the electrode cartridge is received in the opening, and a series of separate spaced electrode plates supported by the support member, each electrode plate having a terminal which extends through the support member from the inner side to project from the outer side.

FIELD OF THE INVENTION

This invention relates to an electrolytic cell. It relates also to an electrode cartridge of the electrolytic cell and to improved electrode plates of the electrode cartridge. In particular, the invention relates to an electrolytic cell, electrode cartridge, and improved electrode plates used in chlorination of salt water swimming pools, spas and the like bodies of water.

BACKGROUND OF THE INVENTION

The chlorination of pools is necessary to prevent unwanted growth of bacteria in the water. Electrolytic chlorination has become a popular method of achieving bacteria free water. Electrolytic chlorination uses common salt which is added to the water located within the pool in combination with an electrolytic cell which is used to produce chlorine. This chlorine is released into the water thereby killing any unwanted bacteria and micro organisms. The process is cost effective, low maintenance and environmentally friendly.

Electrolytic chlorination is commonly achieved using “in-line” electrolytic cells. These “in-line” electrolytic cells are typically plumbed into the return line between the filtration system and the pool. Electrodes plates of the electrolytic cell require periodic cleaning to remove the build up of scale (such as calcium carbonate or calcium hydroxide or magnesium hydroxide) on the electrode plates. The electrode plates may also have to be replaced. The electrode plates can only be effectively cleaned or inspected by removing them from the electrolytic cell. The electrode plates are commonly cleaned by rinsing with acid such as muriatic acid.

U.S. Pat. No. 7,2111,76 describe an electrolytic cell which has a replaceable electrode assembly which is removable from a housing. A cap and a lock ring need to be undone to remove the electrode assembly from the housing. The electrode assembly includes an electric cord permanently connected to an electrode coupling of the electrode assembly. The electrode assembly is replaced by disconnecting the electric cord at an end where it connects to a power module. Undoing the cap and the lock ring may be cumbersome and time consuming. Even when the cap and the lock ring are undone the electrode assembly is still tethered from the electric cord. It would be convenient if the electrode assembly could be transported to be cleaned at a facility away from the electrolytic cell, such as at a basin or the like.

International Patent Application No. PCT/AU2006/001211 discloses a prior art electrolytic cell having electrical connections spot welded to the electrode plates. Welding not only requires extra time to be spent in manufacture but also has some drawbacks in operation. The welding process inevitably damages the grain of the metal used such that the welded area is more susceptible to corrosion than the rest of the electrode plate. It may also be possible for water to penetrate underneath the weld and accelerate corrosion in this area.

OBJECT OF THE INVENTION

It is an object of the invention to overcome or alleviate one or more of the disclosures or provide the consumer with the useful or commercial choice.

SUMMARY OF THE INVENTION

In one form, although not necessary the only or broadest form, the invention relates to an electrolytic cell comprising:

a housing having a channel extending there through and an opening formed in the housing for receiving an electrode cartridge;

an inlet allowing water to pass into the channel;

an outlet allowing water to pass from the channel; and

a removable electrode cartridge comprising:

-   -   a support member having a outer side and an inner side, the         support member being adapted to close off the opening in the         housing when the electrode cartridge is received in the opening;         and     -   a series of separate spaced electrode plates supported by the         support member, each electrode plate having a terminal which         extends through the support member from the inner side to         project from the outer side.

Preferably the series of spaced electrode plates are cantilevered from the support member.

The support member is preferably elongate having opposite ends. Similarly, the opening formed in the housing is elongate to receive at least part of the support member.

The electrolytic cell preferably includes an electrical plug having a number of terminal receiving sockets for receiving the terminals of the electrode plates.

The electrolytic cell preferably includes clip means for releasably clipping the support member to the housing.

The clip means preferably includes a hand operable clip.

The clip is preferably located at one of the ends of the support member.

The housing is preferably curved in the region of the opening and the support member is preferably complementary curved to seat in the opening.

The opening in the housing is preferably rectangular.

The terminal of the electrode plate is preferably unitary with the remainder of the electrode plate.

The electrode plate is preferably integrally formed from a single piece of solid metal. The electrode plate may be formed from any suitable material, such as titanium.

The terminals are preferably in the form of tabs.

One or more edges of the electrode plate may be arcuate in shape.

The electrode plate may have a cut-out which is substantially the same size and shape as the tab.

The support member preferably has a series of apertures through which the terminals extend.

The housing is typically formed from a base and a cap and the opening is located in the cap. Normally the housing is made of plastic, but can be made from other suitable materials.

The invention extends to the removable electrode cartridge as defined and described herein above. Specifically, the invention extends to a removable electrode cartridge comprising:

-   -   a support member having a outer side and an inner side, the         support member being adapted to close off an opening in a         housing when the electrode cartridge is received in the opening;         and     -   a series of separate spaced electrode plates cantilevered from         the support member, each electrode plate having a terminal which         extends through the support member from the inner side to         project from the outer side.

The invention extends to the housing as defined and described herein above having an elongate opening therein for receiving the electrode cartridge.

The invention extends also to one of the unitary electrode plates as defined and described hereinabove.

In another form the invention relates to an electrolytic cell comprising:

a housing having a channel extending there through;

an inlet allowing water to pass into the channel;

an outlet allowing water to pass from the channel; and

a series of electrode plates that fit within the channel of the housing; each electrode plate having a respective terminal which extends through an opening in the housing;

wherein each terminal is able to be received within a respective terminal socket of an electrical plug.

In yet another form the invention resides in a method of electrically connecting a series of plates locating with a housing of an electrolytic cell to a power module, the method including the step of:

connecting an electrical plug having a series of sockets to terminals of a series of plates, each plate having a terminal.

In still yet another form, the invention resides in an electrode plate including:

a plate portion;

a terminal tab being unitary with the plate portion;

wherein a cut-out portion is located within the plate portion which is the same shape and size as the terminal tab.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described with reference to the accompanying figures in which:

FIG. 1 is a perspective view of an electrolytic cell according to an embodiment of the invention;

FIG. 2 is a perspective exploded view of the electrolytic cell as shown in FIG. 1, showing an electrode cartridge of the electrolytic cell removed from a housing of the electrolytic cell;

FIG. 3 is a perspective view from one end of the electrode cartridge as shown in FIG. 2;

FIG. 4 is a perspective view from another end of the electrode cartridge as shown in FIG. 2;

FIG. 5 is a side view of the electrode cartridge as shown in FIG. 2;

FIG. 6 is a perspective view of the electrode cartridge shown in FIG. 2, with all but one of the electrode plates removed from the electrode cartridge;

FIG. 7 is a perspective view of a backing plate of the electrode cartridge as shown in FIG. 6;

FIG. 6 is a perspective view of an electrode plate according to an embodiment of the invention, of the electrode cartridge of FIG. 2;

FIG. 9 is a perspective view of an electrode plate according to an embodiment of the invention;

FIG. 10 is a perspective view of the electrolytic cell of FIG. 1, including a plug connected to the electrode plates of the electrolytic cell; and

FIG. 11 is a perspective view of the plug of FIG. 10.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIGS. 1 and 2 show an electrolytic cell 10 used for chlorination of pool water. The electrolytic cell 10 includes a curved housing 20 and an electrode cartridge 30. The electrode cartridge 30 is releasably and removably mounted to the housing 20 as will be discussed herein below.

The housing 20 is made up of a base 40 and a cap 50. The cap 50 is removably attached to the base 40 by a series of cap bolts 51 which extend around a peripheral flange 52 of the cap 50. Bolt holes 41 are located within the base 40 for location of the cap bolts 51 to attach the cap 50 to the base 40. A seal is located between the flange 52 and the base 40 to ensure a join between the cap 50 and the base 40 is water tight.

The cap 50 has sidewalls 53 and an arched top wall 54 between the sidewalls 53. An opening 60 is located in part of the top wall 54, in which the electrode cartridge 30 is removably received. The opening 60 is generally rectangular.

A hoop 55 is located on the flange 52 at a position adjacent a lower end 61 of the opening 60. A notch 56 is located in the top wall 54 at a position spaced from an upper end 62 of the opening 60. An inlet 80 is located at one end of the base 40 with an outlet 90 located on the other end of the base 40. Both the inlet 80 and the outlet 90 have associated pipe connectors 100 to enable the housing 20 to be connected to associated pipes (not shown). The inlet 80 and outlet 90 are in alignment with each other. However, it should be appreciated that this may not necessarily be the case and is dependent on the design of a pool chlorination system.

A channel 160 in the shape of a spiral is formed in the housing 20 between the inlet 80 and the outlet 90. The channel 160 extends from the inlet 80, through the base 40, through the cap 50, back into the base 40 and out the outlet 90.

The electrode cartridge 30, shown in more detail in FIGS. 3 to 7, includes a support member in the form of a backing plate 110 and a series of separate electrode plates 140 cantilevered from the backing plate 110. The electrode cartridge 30 includes a series of eight electrode plates 140, but it will be appreciated that it may include any number of electrode plates 140. FIG. 6 shows only a single electrode plate 140 mounted to the backing plate 110 and FIG. 7 shows only the backing plate 110.

The backing plate 110 is made of plastics material. The backing plate 110 is generally arcuately curved having a concave side 111 and a convex side 112. The backing plate 110 has an upper end 118 and a lower end 119. A hook 120 is located at the lower end 119. The hook 120 is shaped to hook onto the hoop 55 on the flange 52. Clip means in the form of a clip 130 is located at the upper end 118. The clip 130 is hinged. The clip 130 has a latch 131 at its underside 132, which is shaped to engage the notch 56 in the top wall 54. The clip 130 is operable to clip and un-clip from the cap 50 by manual hand operation of the clip 130.

The backing plate 110 has a raised strip 113 at its concave side 111. The raised strip 113 is shaped to fit within the opening 60 of the housing 20 to close off the opening 60. A peripheral rim 114 of the backing plate 110 surrounds the raised strip 113. The rim 114 abuts part of the top wall 54 surrounding the opening 60 when the raised strip 113 is located in the opening 60. The raised strip 113 and rim 114 ensure a water tight seal between the backing plate 110 and the cap 50 to seal the housing 20. A rubber seal may be formed in the rim 114 to promote the seal. The backing plate 110 has a series of spaced apertures 115 (depicted in FIGS. 6 and 7) extending through the backing plate 110 from the concave side 111 to the convex side 112. The apertures 115 are regularly spaced with respect to one another.

Each electrode plate 140 in the series comprises a plate portion 143 and a terminal in the form of a tab 144 projecting from the plate portion 143. A single electrode plate 140 is depicted in FIG. 8. Referring to FIG. 8, the plate portion 143 has an arcuate outer edge 141 at a proximal end of the electrode plate 140 and an arcuate inner edge 142 at a distal end of the electrode plate 140.

The tab 144 extends from the outer edge 141 of the plate portion 143. The plate portion 143 and tab 144 are unitary and integrally formed with one another. The electrode plate 140 is cut, stamped or otherwise formed from a single piece of flat plate. It should be appreciated that the electrode plates 140 may be sized, shaped and made from a variety of materials which would be evident to a person skilled in the art. The electrode plates 140 are typically stamped or cut from titanium plate coated with platinum or ruthenium. There are no surface irregularities at the juncture between the plate portion 143 and tab 144, making the electrode plate 140 more corrosion proof than if the plate portion 143 and tab 144 were welded to each other.

The electrode plates 140 are fixed to the backing plate 110. The tabs 144 of the electrode plates 140 are received in the apertures 115 of the backing plate 110. The tabs 144 extend through the apertures 115 and project from the convex side 112 of the backing plate 110. The outer edge 141 of each plate portion 143 abuts the raised strip 113 of the backing plate 110. The backing plate 110 may have spaced grooves (not shown) in its concave side 111 in which the outer edges 141 of the plate portions 143 seat. The plate portions 143 cantilever from the backing plate 110. The plate portions 143 are shaped so that they will fit easily within the channel 160 of the curved housing 20. The distal ends of the electrode plates 140 are free from each other and not supported in any way.

FIG. 9 shows another embodiment of an electrode plate 150. The electrode plate 150 is similar to the electrode plate 140, with the only difference being a cut-out 151 in the plate portion 152 of the electrode plate 150. The cut-out 151 is the same size and shape as the tab 153. The cut-out 151 is a slit which extends from the inner edge 154 of the electrode plate 150. The cut-out 151 is formed when cutting or stamping a number of electrode plates 150 from a blank. It will be appreciated that when stamping or cutting the electrode plates 150, the tab 153 of one electrode plate 150 is located in the cut-out 151 of a neighbouring electrode plate 150. This optimizes the number of electrode plates 150 which may be cut or stamped from a particularly sized blank.

FIG. 10 shows the electrolytic cell 10 including an electrical plug 170. The plug 170 is shown separately in FIG. 11. The plug 170 plugs onto the tabs 144 of the electrode plates 140. The plug 170 comprises a body 171 having a number of spaced tab-receiving sockets 172 therein, as depicted in FIG. 11. The slots 172 have electrical contacts therein, which are in electrical contact with the tabs 144, when the tabs 144 are received in corresponding sockets 172. The number of sockets 172 match the number of tabs 144. The plug 170 is connected to a power module (not shown) via an electrical cord 180. Electric current from the power module is supplied to the electrode plates 140 via the electrical cord 180 and the electrical plug 170. Accordingly, each electrode plate 150 is individually supplied with power from the socket 172. The plug 170 optionally includes a bridge rectifier. The bridge rectifier ensures that the polarity at the different electrical contacts in the plug 170 remain the same, regardless of the polarity at the input to the plug from the power module. The bridge rectifier provides reverse polarity protection. That is, it ensures that electrode plates 140 which are cathodes remain cathodes and the electrode plates which are anodes remain anodes, irrespective of the power source used.

An interference fit between the tabs 144 and the electrical contacts with in the sockets 172 secures the electrical plug 170 to the tabs 144. The electrical plug 170 can be plugged onto the tabs 144 by hand and similarly un-plugged by hand.

FIGS. 1 and 10 show the electrolytic cell 10 in a condition wherein the electrode cartridge 30 is releasably mounted to the housing 20 by being clip-locked thereto. The cartridge 30 is clip-locked to the housing 20 by first introducing the hook 120 of the backing plate 110 into the hoop 55, and then introducing the latch 131 of the clip 130 into the notch 56. The electrical plug 170 then plugs onto the tabs 144 to electrically connect the electrolytic cell 10 to the power module. In use, water flows into the channel 160 through the inlet 80. The direction of water flow through the channel 160 is indicated by arrows 43 located on the base 40. The water passes through the base 40 and into the cap 50 passing over the electrode plates 140. Current is applied to the electrode plates 140 via the electrical plug 170 to produce electrolysis and cause chlorine to be released into the water.

After extended use the electrode plates 140 have to be cleaned or the electrode plates 140 replaced by replacing the electrode cartridge 30. In both instances the electrode cartridge 30 needs to be removed from the housing 20. The electrode cartridge 30 is removed by un-plugging the electrical plug 170 from the tabs 144 and then un-clipping the electrical cartridge 30 from the housing 20. To un-clip the electrode cartridge 30, the clip 130 is operated to un-latch the latch 131 from the notch 56. The electrode cartridge 30 is then displaced to un-hook the hook 120 from the hoop 55, freeing the electrode cartridge 30 from the housing 20. A new electrode cartridge can replace the old electrode cartridge 30 by mounting the new electrode cartridge to the housing 20 as described. It is unnecessary to unplug the plug 170 from the electrode cartridge 30 if the electrodes 140 only need cleaning or for inspection purposes, but it may be convenient to do so if the electrode cartridge 30 is to be transported for cleaning.

The electrolytic cell 10 provides for easy inspection, cleaning and replacement of the electrode cartridge 30. Removal of the electrode cartridge 30 from the housing 20 is simpler and less cumbersome when compared to traditional electrolytic cells, as shown in U.S. Pat. No. 72/211,176 and International Patent Application No. PCT/AU2006/001211. The prior art systems have the electrode cartridge/assembly tethered from an electrical cord after being removed from their housings. Simple electric connection to the electrode cartridge 30 is provided by the plug 170 of the present invention. The plug 170 and electrode cartridge 30 are simple to unplug for replacement or transport of the electrode cartridge 30.

It will also be appreciated that various other changes and modifications may be made to the embodiment described without departing from the spirit and scope of the invention. 

1. An electrolytic cell comprising: a housing having a channel extending there through and an opening formed in the housing for receiving an electrode cartridge; an inlet allowing water to pass into the channel; an outlet allowing water to pass from the channel; and a removable electrode cartridge comprising: a support member having a outer side and an inner side, the support member being adapted to close off the opening in the housing when the electrode cartridge is received in the opening; and a series of separate spaced electrode plates supported by the support member, each electrode plate having a terminal which extends through the support member from the inner side to project from the outer side.
 2. The electrolytic cell of claim 1 wherein the series of spaced electrode plates are cantilevered from the support member.
 3. The electrolytic cell of claim 1 wherein the electrolytic cell includes an electrical plug having a number of terminal receiving sockets for receiving the terminals of the electrode plates.
 4. The electrolytic cell of claim 1 wherein the electrolytic cell includes clip means for releasably clipping the support member to the housing.
 5. The electrolytic cell of claim 1 wherein the terminal of the electrode plates is unitary with the remainder of the electrode plate.
 6. The electrolytic cell of claim 1 wherein the electrode plate is integrally formed from a single piece of solid metal.
 7. The electrolytic cell of claim 1 wherein the terminals are in the form of tabs.
 8. The electrolytic cell of claim 7 wherein the electrode plate has a cut-out which is substantially the same size and shape as the tab.
 9. The electrolytic cell of claim 1 wherein one or more edges of the electrode plates are arcuate in shape.
 10. The electrolytic cell of claim 1 wherein the support member has a series of apertures through which the terminals extend.
 11. An electrode cartridge comprising: a support member having a outer side and an inner side, the support member being adapted to close off an opening in a housing when the electrode cartridge is received in the opening; and a series of separate spaced electrode plates cantilevered from the support member, each electrode plate having a terminal which extends through the support member from the inner side to project from the outer side.
 12. An electrolytic cell comprising: a housing having a channel extending there through; an inlet allowing water to pass into the channel; an outlet allowing water to pass from the channel; and a series of electrode plates that fit with the channel of the housing, each electrode plate having a respective terminal which extends through an opening in the housing; wherein each terminal is able to be received within a respective terminal socket of an electrical plug.
 13. A method of electrically connecting a series of plates locating with a housing of an electrolytic cell to a power module, the method including the step of: connecting an electrical plug having a series of sockets to terminals of a series of plates, each plate having a terminal.
 14. A electrode plate including: a plate portion; a terminal tab being unitary with the plate portion; wherein a cut-out portion is located within the plate portion which is the same shape and size as the terminal tab. 